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Zitiervorschau

OPERATION INSTRUCTION MANUAL FOR ELECTRIC MODULATING ACTUATORS

CHANGZHOU POWER STATION AUXILIARY EQUIPMENT WORKS, Ltd.

THE PEOPLE’S REPUBLIC OF CHINA

1. GENERAL DESCRIPTION This series of products can be used with model III and model II instruments and model S auxiliary control unit, they can precisely and reliably control gate valve, isolating valve, throttle valve and all sorts of control valves. They can apply to closed-loop control system of industrial process. They mainly come in to service in the area of power station, metallurgy, chemical industry, sewage treatment, ventilation, air conditioning and so on. These products have two models according to working environment: flameproof model and common model; two types according to structure and frame: integrated type and separated type. For the separated type, the digital servo amplifier and the actuator have been installed separately; for the integrated type, the servo amplifier has been installed inside the actuator. The performance of these products meets with the requirements of Std. JB/T8219-1999 Electric Actuators for Industrial-process Measurement and Control Systems. For flameproof model, the performance satisfies the requirements of Std. GB3836.1-2000 Electrical Apparatus for Explosive Gas Atmospheres ―Part 1: General Requirements and Std. GB3836.2-2000 Electrical Apparatus for Explosive Gas Atmospheres ―Part 2: Flameproof Enclosure “d”. The product characteristics are as following: 1.Provided with series 51 single-chip as main control unit, the control of electric actuator is more flexible and reliable. 2.Provided with perfect protection circuit, the open and close directions are interlocked to prevent it from motor overheat, over torque and over travel. 3.AC contactor replaced by solid state relay, the valve motor can start 1200 cycles per hour within the range of temperature rise, and service life of valve motor is prolonged. 4.Sealed in bellows or sleeve, and lubricated with thin oil, screw rod and nut of the electric linear actuator will hardly get stuck, and the service life is prolonged.

2. REPRESENTATION OF PRODUCT TYPE 1 □

2 □

—

3 □

/

4 □

—

5 □

6 □

7 □

Product type

1 □

2 □

Torque or thrust

— 3 □

/

speed 4 □

Travel or Max. rev

— 5 □ 6 □ 7 □

ZBTZ: linear to table 1 ZBTD: multi-turn to table 2 ZCTD: multi-turn to table 2 QBTJ: part-turn to table 3 DQTJ: part-turn to table4 Linear: output thrust N Multi-turn or part-turn: torque×10N•m Linear: speed mm/s Multi-turn or part-turn: speed Linear: travel mm Multi-turn:

r/min

Max.rev

Connecting cycles/hour (four specifications: 100, 320, 630, 1200) times Symbol of flameproof type: B Motor, Y : single phase; without letter: three phases

For example: ZB1TZ16000―1/40 － 320B represents the linear electrical actuator with output thrust of 16000N, output speed of 1 mm/s, travel of 40 mm, connecting times of 320 cycles/hour, explosion-proof type (flameproof type). In addition, connection dimensions of multi-turn type are divided into two modes: torque mode and thrust mode. For thrust mode, 2 is followed by letter T; and for torque mode, there is no letter representation.

1

3. SERVICE ENVIRONMENT 1. Power Supply: three phases: 380V±10%; 50Hz±1%; single phase: 220~230V 50Hz 2. Temperature: integrated model -40℃~+55℃; separated model -40℃~+70℃; electric control box 0~50℃ 3. Relative humidity: electric actuator≤95%, electric control box 10%~70% 4. Input signal: 4～20mA DC; Output signal: 4~20mA DC 5．Dead zone: 1%~12.5% adjustable 6．Motion forbidden time: 2s~25s adjustable 7. Duty time: S5, minimum load held ratio 25%, maximum operating times 1200 cycles/hour 8. Protection class: IP55 (IP67 for specific order) 9. Flameproof class: ExdibⅡBT4 (ExdibⅡCT4 for specific order of ZCTD and DQTJ ) The special requirements are based on the contract.

4. MAIN TECHNICAL SPECIFICATIONS 1. ZBTZ type ZB1TZ Thrust N 4000 6300 10000 Torque N·m 30 40 50 travel mm 80; 40 Speed mm/s 1mm/s (12r/min) 3-ph type YDTF-(C)80M2-4Ⅰ 380V power 0.25kW motor current 0.62A Note：ZB1TZ may select and use single-phase (220V) motor.

table 1 ZB2TZ 25000 150

16000 80

1.2mm/s (12r/min) YDTF-(C)100M1-4Ⅱ 0.55kW 1.45A

2. ZBTD and ZCTD type

table 2

type

motor power kW

current A

YDTF80M2-4Ⅰ 0.25 0.62 YDTF80L-4Ⅰ 0.37 1.22 YDTF100M1-4Ⅱ 0.55 1.45 10 ZB2TD30 YDTF100L1-4Ⅱ 1.1 2.76 YDTF100L2-4Ⅱ 1.5 3.65 YDTF2100L2-4Ⅳ 1.5 3.65 45 ZC4TD90 YDTF2132M1-4Ⅳ 2.2 4.95 YDTF2132M2-4Ⅳ 3.0 6.6 YDTF2132L1-4Ⅴ 4.0 8.6 ZC5TD120 160 YDTF2132L2-4Ⅴ 5.5 11.5 Note: ZB1TD28 may select and use single-phase (220V) motor. ZB1TD28

Output r/min 12 18 24 Output torque N·m 50 35 25 80 55 40 150 100 75 300 200 150 250 180 450 300 200 600 400 300 900 600 450 1200 800 600 1600 1000 750

3. QBTJ

table 3 motor

type QB1TJ105 QB2TJ 25 QB2TJ 50 QB3TJ2100 00

type

power kW

current A

YQTF63M2-4Ⅰ YQTF63L2-4Ⅱ YQTF63L2-4Ⅱ YQTF80L-4Ⅲ

0.06 0.12 0.15 0.55

0.25 0.39 0.5 1.61 2

Output torque N·m

Time of 90° rotation S

50～100 250 500 1000～2000

15

Note：QB1TJ105 and QB2TJ 25 may select and use single-phase (220V) motor. 4. DQTJ

table 4 Second stage torque power Hand Time of 90° type First stage rotation S N·m kW radio type radio DQ3TJ400 4000 ZC4TD40-18 2.2 46 DJ3A 55 2035 DQ3TJ600 6000 ZC4TD60-18 3.0 DQ4TJ800 8000 73 ZC4TD90-12 DJ4A 58 3.0 2146 DQ4TJ1000 10000 DQ5TJ1600 16000 68 ZC5TD160-12 DJ5A 54 5.5 2214 Note: For flame-proof models, “B” should be added to the type representation in the above 4 parameter tables. E.g. Actuator ZC4TD90B .

FUNCTIONING PRINCIPLE AND STRUCTURAL CHARACTERISTICS 5.FUNCTIONING 5.1 Functioning Principle Electric modulating actuator is the main operating element of the auto-control system. It’s driven by three phases or single phase alternating current. It can receive standard signal (including the analog and digital quantity), transform this signal into corresponding mechanical displacement ( L) and operate the modulating mechanism and fulfill the automatic adjustment. For the system block diagram of electric modulating actuator , see Fig. 1

4~20mA

electric manipulator

MCU digital control module

motor driving module

from control system indication of position feedback control system

special motor for modulating

reducer

α

position signal transmitter integrated model electric modulating actuator

Fig.1 When the electric modulating actuator is in automatic mode, the MCU digital control module in the actuator receives the standard analog signals (4~20mA, DC) from auto-control system, and compares them with the standard analog signals (4~20mA, DC) coming from the position transmitter in the actuator. If the difference is more than the dead zone set by user, the MCU digital control module will emit control signals to drive the electric modulating actuator to run in the direction to reduce the deviation between the both, till the deviation is less than or equal to the dead zone set in the electric actuator; the MCU digital control module will emit again control signals, to make the electric actuator stop. When the electric modulating actuator is in manual control mode, it can be operated with the buttons in the electric compartment of the actuator. 5.2 Structural Characteristics 5.2.1 Special electric motor Special electric motor for control valve is the driving component of the electric modulating actuator; its characteristic requirements are different from the common motors. As the actuator works frequently and is often in starting condition, the motor is required to have the characteristics of higher starting torque with less rotating inertia and lower starting current to prevent it from over heat due to frequent starting, and to be able to provide with enough torque to success from static status to operating. To increase the reliability of the electric actuator, and to overcome inertia of system, electric modulating actuator adopts the brake measure with reverse power connection through MCU digital control module. 3

5.2.2 Reducer The reducer is used to change the motor output power of high speed and little torque into the actuator output power of low speed and great torque. Motor/manual clutch is semi-automatic, i.e. for manual drive, pull the lever in the arrow direction, and for motor drive, it will turn back automatically by motor operation. 5.2.3 Position Signal Transmitter (BS-2) The signal transmitter converts axial displace (L) of valve stem into DC 4~20mA signals linearly in two channels: one for closed-loop negative feedback signals from the proportional electric actuator, and another for position signals from output shaft of electric actuator, the position signals indicate valve position. The signal transmitter is composed by accurate electro-conductive plastics rotating potentiometer (as sensor) and BS-2 module. With the structure adopting rotating accurate electro-conductive plastics potentiometer, the circuit is simple, the linearity is high, and the service life is as long as 3 million cycles. 5.2.4 Travel Limiter, Torque Limiter, and Position Indicator The travel limiter in the actuator is an electric position limit. The torque limiter is a protective structure to protect the actuator and the valve. The position indicator is to indicate the open or closed direction and the position of the valve. For the structure of the travel limiter, torque limiter and position indicator in the ZBTZ linear electric modulating actuator, see Chapter 7 Installation and Setting. 5.2.5 Composition and Functions of MCU Digital Control Module The MCU digital control module is composed of CPU chip, A/D converting circuit, return circuit, scale converting circuit, hand-control electric driving circuit, regulating circuit for dead zone and action forbidden time. The system block diagram is shown in Fig.2.

Return circuit regulating circuit for dead zone and action forbidden time

A/D conversion circuit

CPU chip

scale conversion circuit

From control system

4~20mA Signals From position

hand control driving circuit

electric

Fig.2 The system block diagram of MCU The CPU chip adopts 89C2051 single chip from ATMEL Co., and is the core control unit of the MCU digital control module. It receives signals from the other circuits and coordinates all digital control modules via calculating. The scale converting circuit converts the DC 4~20mA signals coming from auto-control system and from position transmitter into the 1~5V voltage signals. Receiving the 1~5V voltage signals coming from scale converting circuit, the A/D converting circuit operates calculations of the set signals and position signals with sampling arithmetic under the control of the CPU chip, and converts analog quantity into digital quantity for CPU chip to use. The return circuit restores the single chip and activates it. At the same time, the return circuit monitors and controls the electric source of the MCU digital control module. When the electric source of system declines to a certain value, the return circuit restores the single chip to guarantee the normal operation. In addition, this return circuit is also provided with function of watch-dog, to ensure stable and reliable running of control programs The hand-control electric operating circuit is to drive electric actuator through manual operation on press button. The regulating circuit for dead zone is to interdict any motion of the actuator thereby to eliminate vibration and sway phenomena when the differential between the input signals and feedback signals is within the dead zone The regulating circuit for motion forbidden time plays the role of electronic timer; once the actuator reaches stopping position, it will interdict further motion of actuator within regulated time. 5.2.6. Electric Control Compartment For electrical control of Type QBTJ Integral Angular Modulating Actuator, refer to Fig. 3. For linear or 4

multi-turn modulating actuators, composition of electrical control is the same of Type QBTJ. But disposal and distribution may be different.

1. terminal block 2. MCU digital control modules 3. exchanging switch 4. button 5. microswitch for travel 6. position indicator 7. solid state relays 8. fuse 9. heating resistance 10. 4～20mA signal transmitter 11. module assembly

Fig.3 electric control compartment

OVERALL SIZE AND CONNECTION DIMENSIONS 6．OVERALL 6.1 ZBTZ，see Fig.4 and table 5

Fig.4

outline drawing of ZB1TZ

5

Overall size and connection dimensions Thrust A1 type A N (H9) ZB1TZ

4000 6300 10000 16000

M12×1.25

φ80

table 5 A2

A3

B

C

φ105

φ150

123

φ12

H

H1

40

326

80 406 ZB2TZ 25000 M16×1.5 φ95 φ118 φ210 130 φ14 Note: Size B is the protrusion length of user’s pull rod, including screwed in depth (it is 18 for ZB1TZ, and 22 for ZB2TZ.) 6.2 ZBTD and ZCTD, see Fig.5～Fig.8 and table6～table8

Fig.5 outline drawings of

ZBTD

Overall size of ZBTD type ZB1TD28 ZB2TD1030

A 276 306

table 6 B 521 561

C 262 319

D 230 305

G 212 254

H 301 337

K φ250 φ360

M determined by user

Fig.6 outline drawings of ZCTD

Overall size of ZCTD 型号 B1 B2 45 ZC4TD90 375 488

D1 φ280

H1 255

H2 determined 6

H3 94

H4 115

L1 305,316

L2 185

table 7 L3 397

ZC5TD120 160

417

582

φ400

241

by user

112

130

381

205

Fig.8 connection dimensions of thrust mode

Fig.7 connection dimensions of torque mode Connection dimensions of ZBTD and ZCTD 型号 2 8

ZB1TD ZB2TD1030 ZC4TD4590 ZC5TD120 160

428

table 8

D

D1

Torque mode JB2920 D2 h1 f h d1 d2

145

120

90

2

4

8

30

185

160

125

2

4

10

275

235

180

2

5

330

285

220

3

6

Thrust mode D D1 D2

GB12222 d1 d

d

n

flange

L

n

45

M10

4

F10

125

102

70

3

T28

M10

48

4

42

58

M12

4

F14

175

140

100

4

T36

M16

60

4

14

62*

82

M20

4

F25

300

254

200

5

T60

M16

114

8

16

73

98

M24

4

F30

350

298

230

5

T70

M20

130

8

f

6.3 QBTJ, see Fig.9,Fig.10 and table9, table10

Fig.9 outline drawing of QBTJ

L1

L2

QB1TJ5 70 2 QB1TJ10 QB2TJ25 3 95 QB2TJ50 10 QB3TJ100 150 22 QB3TJ200 Overall dimensions of QBTJ

L3

L4

L5

322

63

164

353 360

81

190

397

132

198

L6 normal

Flame-proof

182 303 215

L7 281 286 310 342 423

L8

φD

261

145

300

190

325

460

table 9 7

A view

Fig.10 connection dimensions of QBT type d1(H9) d2(f8) QB1TJ5 22 35 QB1TJ10 28 55 QB2TJ25 42 70 QB2TJ50 50 85 QB3TJ100 60 100 QB3TJ200 80 130

d3 65 90 125 150 175 210

connection dimensions of QBTJ d4 M6 M8 M10 M12 M16 M20

d5 50 70 102 125 140 165

h1 14 16 20 24 30 35

h2 3 3 3 3 4 5

h3 30 35 50 57 65 80

h4 24.8 31.3 45.3 53.8 64.4 85.4

table 10 b(D10) 6 8 12 14 18 22

6.4 DQTJ, see Fig.11 and table 11 ,table 12

Fig.11 outline drawings and connection dimensions of DQTJ

Overall size of DQTJ type Amax B DQ3TJ400 523 397 600 00 DQ4TJ81000 588 397 DQ5TJ1600 608 428

C 198 231 316

E 292 320 383

F 288 330 436

H 250 275 321

Connection dimensions of DQTJ

J 440 568 695

K 538 686 751

L1 115 138 165

L2 380 393 424

P 195 252 315

table Q T φ280 340 φ280 410 φ400 495

11 V 132 130 165

table 12 8

type D1(f8) D2 D3 d(H9) b×L b1 h M 400 DQ3TJ600 φ200 φ254 φ300 φ100 28×110 5 5 8-M16 00 DQ4TJ81000 φ230 φ298 φ350 φ120 2-32×150 5 5 8-M20 DQ5TJ1600 φ260 φ356 φ415 φ160 2-40×200 5 5 8-M30 Note: The position of double-key in Fig.11 indicates full closing of valve. And for the case of single key, position of key is perpendicular to the motor shaft axis.

7. SCHEMATIC DIAGRAM AND WIRING DIAGRAM 1

2

3 8

4 9

13 18

14 19 24

23 28 29 30 31

Outline of various terminal blocks of each type actuator is represented in Fig. 12. Among them, A is used for all flame-proof models; B is used for ZBTZ, ZBTD, and ZCTD; C is used for QBTJ (number of terminal may be increased to 14). Schematic diagram of ZBT and QBT is illustrated in Fig. 13. Schematic diagram of ZCTD is illustrated in Fig. 14. Wiring diagram of ZBT and QBT is illustrated in Fig. 15. Wiring diagram of ZCTD is illustrated in Fig. 16. Single-phase wiring diagram of ZBT and QBT is illustrated in Fig. 17. B A

1

1

2 3 4 5 6 7 8 9 10 11 12

2 3 4 5 6 7 8 9 10 11 12 C

Fig. 12 Various terminal blocks of each type actuator

Meaning of code in schematic diagram and wiring diagram: O— open C— close SL—travel limit switch ST—torque limit switch HR is the lamp indicating opening HG is the lamp indicating closing HY is the lamp indicating status RJ is the thermal protector of motor

9

Note: Components in dash line block are used for single-phase motor only. Terminal 1 and Terminal 4 are connected to power supply of 220 V AC. Terminal 2 and Terminal 3 are not wired. Fig.13 schematic diagram of ZBT, QBT 10

Fig.14 schematic diagram of ZCTD 11

+

Fig.15 wiring diagram of ZBT,QBT 12

J5-4 J5-3 J5-2 J5-1 4(N)

2

1

J5

LED4

3

2

1

1

J1

J4

2

5

3 2 1

R-2

6,8

J1-4 LED-5B LED-1B LED+

4

J3 J4-1

R-3

R-1 4-20mA

J4-2 7

7

5

J2

H

T1 T2

6

BS-2

4

J2-3 J2-2

3

3

2 1

50 LED-5B

FU RJ

M 3～

STo1

STc1

+

25

75

0

100

LED-1B

-

%

LED-

LED+

9 KMC

KMO

11 5A 5B 1A 1B

10

12

6A 6B 2A 2B

SLo

LED+ +

+

-

-

J2-2 J4-1

O

SLc

C J2-3 5 J4-2 4 3 2 1 STc1 2A

5 4 3 6A STo1 2 1

J1-4

STo 1(U)

2(V)

STc

3(W) 3 KNX

RH

J5-4 J5-1

J5-2

J5-3

Fig.16 wiring diagram of ZCTD 13

4(N)

J5-4 J5-3 J5-2 J5-1

R-3(ZBT) R-1 R-1(QBT) 5 J1

J3 1 2

3 2 1

J4

LED-5B

LEDJ1-3 J1-2 LED+

4

1

R-1(ZBT) R-3(QBT)

6

7

J2

J1-3

1

LED-5B RJ

1(L)

5 4 3 2

5 4 3 2

LED-1B

1

LED-5B

LED+

4(N) RH

J2-3 J2-2 J2-1

3

FU

BS-2

4

2

1(L)

LED-

LED+

H

T1 T2

7

5

LED-1B

4～20mA

M J2-1

J1-2

2

LED-1B

3

J2-3

4

2

2A

1

J2-2

J5

J3-1

LED

R-2

6,8

6A

4(N)

1

J2-1 9

11 5A 5B 1A 1B

10

12

6A 6B 2A 2B

4(N)

KNX J5-4 J5-1

J5-2

J5-3

Fig.17 wiring diagram (single phase) of ZBT, QBT 14

J1-3

12

J2-2

10

J2-3

11

LED-5B

1(L)

9

LED-1B

SSR

J1-2

SSR

8. INSTALLATION AND SETTING 8.1 installation and wiring To install the integrated electric modulating actuator, enough space must be left so as to make easier for local hand-operating and dismounting for maintenance. During the maintenance, the electric box cover and the entrance of wires must be sealed, and the entrance nut must be screwed tightly to prevent the electric box from moisture and rainwater. The service environment such as temperature and relative humidity for electric modulating actuator must be conformed to the requirements described in Chapter 3. Before electric connecting, the electric power must be cut off. Internal wiring of the actuator is finished before delivery; user only needs to connect the external wires to terminals inside the compartment of electric actuator according to wiring diagram. During arrangement, wires transmitting the 4~20mA current signals must be separated from power lines; shielded twist pair wire is recommended to cut off interfering coupling channel. Put the switch “manual/auto” in the installation board to “manual”; at the same time, put the valve on the medium position and turn on 3-phase electric power. When the button “open” is pressed, the actuator will run in “open” direction and the needle of position indicator will point to “open”; or, when the button “close” is pressed, the actuator will run in “close” direction and the needle of position indicator will turn to “close”, that means the phase sequence of 3-phase AC power supply for electric actuator conforms to the phase sequence required, and the electric actuator runs in normal state. When the button “open” or “close” is pressed, the electric actuator will run and the needle of position indicator will turn in the reverse direction of button, that means the phase sequence of 3-phase AC power supply for electric actuator is reversed, user must put off the power and exchange two arbitrary phases of the 3-phase AC power supply (for example, exchange the lines no. 2 and no. 3 on the terminal block) to correct the phase sequence. The electric actuator can run in normal state only when the phase sequence of 3-phase AC power supply conforms to the sequence required by electric actuator. 8.2 Setting of travel limiter (The arrow indicating the rotation direction of the adjusting axis is depended on the object) 8.2.1 ZBTZ, ZBTD, ZCTD and DQTJ, see Fig.19 （1）Setting of the valve “complete close” position: ① Turn the hand lever of manual/auto clutch in the arrow direction, operate manually the valve to close completely, and take it back a little from this position. ②Press down top axle with a screwdriver, and rotate it 90º till it is clipped. ③ Rotate adjusting axle for “close” in the arrow direction till the little protuberant bar happens to be approximately in the consistent direction of the two arrows on both sides. ④ Rotate the top axle back to the original position. （2）Setting of the valve “complete open” position. ① After the setting of the valve “complete close” position, open manually the valve just before “complete Open” position (approximately 95% of total travel is recommended). ② Press down top axle with a screwdriver, and rotate it 90º till it is clipped. ③ Rotate adjusting axle for “open” in the arrow direction till the little protuberant bar happens to be approximately in the consistent direction of the two arrows on both sides. ④ Rotate the top axle back to the original position. When adjusting of ZBTZ actuator, incorporate the screwed depth if pull rod, pin and scaled indicator in Fig.20. 8.2.2 QBTJ, see Fig.21 Travel mechanism is as shown in Fig.12. The mechanism is provided with four units of “ opening ”， “clothing”，“MED1”and “MED2”.Microswitch for opening, i.e. SLo in the figure, is used to control valve position during opening travel. Microswitch for closing, i.e. SLc in the figure, is used to control valve position during closing travel. MED1 and MED2 marked respectively SLo1 and SLc1, are used to control the medium position, limit position of opening or closing. Adjustment of travel mechanism is for the purpose of making cam of travel mechanism press microswitch precisely and transmit control signal when valve reaches the required position. Adjusting procedure: ① Rotate handwheel to make valve seat. ② Remove screw and dial, rotate setting axle for closing to make the cam of closing just touch SLc microswitch (while click is heard). ③ Open the valve to about 50% of travel. Then close the valve by electric operation to check if the valve stops 15

at required position. If it does not meet the requirement, continue above micro adjusting of cam until it meets the requirement. ④ Open the valve to complete opening, rotate setting axle for opening to make the cam of opening just touch SLo microswitch. ( while click is heard.) ⑤ Close the valve to about 50% of travel, open the valve by electric operation to check if the valve stops at required position. If it does not meet the requirement, continue adjusting until it meets the requirement. ⑥ Adjustment of medium position: Users may use MED1 and MED2 for medium position in opening or closing direction. （ or complete opening, complete closing ） Adjusting procedure is the same of above adjusting in opening or closing direction. After the adjusting is finished, mount the dial, then repeat electric operation to check for 1～2 times.

vent port

open

close stopping pin

wiring terminal

adjust axle for closing

top axle

drive roller

adjust axle for opening

valve stem

pull rod of control valve

Fig.19 travel limiter of ZBT,ZCT(DQT)

Fig.20 internal structure of ZBTZ

Fig.21 travel limiter of QBTJ 16

8.3 Setting of torque 8.3.1 ZBTZ, ZBTD, ZCTD and DQTJ, see Fig.22 Scale dial

Microswitches

Regulating spacer

Locking plate

For structure of torque limiter, see Fig. 22. The torque limiter has been preset before delivery according to ordering specifications and the set value is filled in the conformation certificate. So the torque limiter does not need Screw

setting generally. If the set value needs resetting, open the cover of the electric compartment, remove the screw on installation board and then Fig.22 torque limiter of ZBT, ZCT(DQT) reset it, looking for corresponding scale value on the torque curve in the conformation certificate. Setting procedure is as below: loosen the screw, set adjusting arm to corresponding scale value and then tighten the screw. 8.3.2 QBTJ, see Fig.23

1. Action strip 2. Gear spindle 3. Nut 4. Adjustment crew 5. Sector plate 6. Cam 7. Swing pin 8. Swing strip 9. Microswitch for closing 10. Microswitch for opening

Fig.23 torque limiter of QBTJ 1．Connecting flange 2. Worm wheel 3. Setting screw for opening 4. Setting screw for closing 5. Nut 6. Sealing pad 7. Gland nut

Fig.24 mechanical stopping 17

⑴. Adjustment for closing stopped by torque limit. ① Rotate adjusting screw 4 for closing torque and make the arrow point to “min”; ② Then operate the valve closing by electric drive. If microswitch of torque limit is pressed to act and the valve stem does not rotate or the valve does not close to seat, it means that the torque value preset is too small. The setting screw may be adjusted (move a scale towards max) , operate the valve by electric drive once again. Increase the output torque value gradually in this way until the valve is seated. ⑵ Adjustment for closing by mechanical stopping (Fig. 24) ① Operate the valve by handwheel until it is seated (precise position). ② Adjust the setting screw 4 for closing and make it just touch the project part of output shaft. Then tighten nut 5 and gland nut 7. ③ Increase the output torque value gradually in the same way as described in 1 until the valve is seated. ④ Addition: After the torque limit is set up, if the position of valve needs a little resetting, setting screw may be reset and torque limit does not need resetting. ⑶ Adjustment for opening stopped by torque limit or mechanical stopping is the same of 1 and 2 for closing. Instead of adjusting screw and setting screw for closing, adjusting screw for opening on torque limit and setting screw for opening need adjusting. 8.4 Adjustment of position indicator For the structure of position indicator, see Fig. 25 and Fig.26 On the dial of indicator, there are three flashing diodes. Among others, the yellow indicates the state, constant light means auto-operation of actuator (i.e. auto-control with 4~20mA signals); flashing white light means manual control (electric operating by manual control), i.e. clicking the buttons (red for “open”, green for “close”) on installation board will make actuator open or close the valve. The red light means motion in “open” direction, the green light means motion in “close” direction. Close completely the valve by electric operation or by handwheel. Rotate the needle and make it point at “close” on the dial. Open completely the valve by electric operation or by handwheel, remain “close” dial fixed, rotate “open” dial to the position of needle. After the setting, fix the installation board and tighten fix screws

Pointer

Fig.25

position indicator of ZBT, ZCT(DQT)

18

WDD32

Fig.26 position indicator of QBTD 8.5 Setting of position signals transmitter (BS-2) (see Fig. 27) From complete open to complete close for valve, the rotation angle of conductive plastic potentiometer must be comprised between 150º~320º, to guarantee a normal function of the 4~20mA position signals transmitter. Put the switch “auto/manual” on installation board to “manual” position. Press the button (clicking) to drive the valve completely closed. Or push the lever of manual/motor to manual state and drive the valve completely closed by handwheel. Loosen the fix screws in conductive plastic potentiometer, rotate its axle in close direction to zero position, measure the current between No.5 and No.6 terminals with a multimeter switched to current measurement. If the measuring result approaches 4mA, tighten the screw. (Note: two ends of the conductive plastic potentiometer are without limit.) Adjust the potentiometer T1 (ZERO) in the 4~20mA position signals transmitter, till the output current is 4.1mA. Press the “open” button (electric operation) to open the valve completely. Adjust the potentiometer T2 (SPAN) in the 4~20mA position signals transmitter, till Fig.27 position signal transmitter the output current is 19.9mA. As the wiring between the potentiometer and BS-2 in Fig.27, real line is used for ZBT and ZCT(including DQT), and dash line is used for QBTJ. When there is current output, indicating lamp within the tramsmitter lights, and the brightness incteases along with the current increment. 8.6 Setting of dead zone and motion forbidden time The setting of dead zone means: user will set dead zone and adjust potentiometer according his own requirements, the clockwise direction for increase of dead zone. The adjusting range is 1%~12.5%, the defaulting range is 5%. User can adjust motion forbidden time potentiometer according to his own requirements, the clockwise direction for increase of motion forbidden time. The adjusting range is 2~25 seconds, the defaulting range is 5 seconds. 8.7 Preparations for operation At first input 4~20mA current control signals, then put the auto/manual switch on installation board to auto state, and turn on the power supply at last to make the actuator run.

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Fig.28 MCU control module

9. TROUBLE SHOOTING 9.1. When turning on the power supply, the circuit breaker trips. Measure the power output ends of the solid-state relay (SSR) with on off range of a universal meter. If it is a short circuit, the solid-state relay is burnt. The solid-state relay must be replaced with a new one. 9.2. When the power supply is turned on, if the yellow lamp of mode indicating “HY” on position indicator does not light, and all lamps on transmitter BS-2 of 4~20 mA do not light. Measure the voltage between Terminals J3-1 and J3-2 on MCU digital control module with a universal meter. If the voltage is 220 V AC, the module is damaged, it shall be replaced. If there is no voltage between them, please check if the thermal protector in the motor or the fuse is conducting. 9.3. When the actuator is in automatic status and there is control signal input of 4~20 Ma, the actuator is not able to modulate valve position according to control signal. Check and remove the trouble as following: 9.3.1 Measure and confirm that current control signal has been inputted the actuator. 9.3.2 If lamps on transmitter BS-2 of 4~20 mA do not light, the transmitter is in trouble. Check the wiring or replace it. 9.3.3 Check if the axis of the conductive plastic potentiometer is rotatable. If it is not rotatable, then check if corresponding mechanism drive is normal; if it is rotatable and the output current is constant, then the conductive plastic potentiometer or transmitter BS-2 is damaged. Replace it. 9.4. If the responding is not sensitive; the deadband is too wide or the time of action forbidden is too long. Then the deadband or the time of action forbidden needs readjusting. 9.5. When the phase sequence is correct and the actuator is in electrical operation with manual control mode, if press the “open” (“close”) button and no action responds; and press “close” (“open”) button, the click mode is changed into self-hold, then travel switch or torque switch in “open” (“close”) direction may be failed. Check and replace it. 9.6. When the valve is in remote control mode, i.e. the yellow lamp lights steadily, the valve is not able to receive 4~20 mA DC signal from DCS, check if Terminal 7(+) and Terminal 8(-) on terminal block is connected reversely. If the connection is correct, then the A/D convertor may be damaged. It is necessary to replace the MCU digital control module.

10. CAUTIONS 10.1 Prevent the glass of window for valve position from any collision with hard things. 10.2 Before installation, the electric actuator must be deposited indoor in a clean and dry environment. If it is deposited outdoor, it must be lifted off earth with a certain height and be shielded from rainwater. 10.3 weather. Before the electric box is opened, the power supply must be turned off. When it is remounted, the cover must be tightened close. 10.4 Before manual operation, pull (or push) the lever of motor/manual clutch in the arrow direction. If it could not be pushed down, rotate the handwheel while pushing. After the lever is pushed to manual position, the actuator can be manually operated. The rotation of handwheel shall be the same of output shaft. Facing to handwheel, the clockwise rotation of handwheel is “close” generally, and the counterclockwise is “open”. While electric operating, the lever will turn back to original position automatically, do not turn it back by hand. 10.5 The housing is filled with semi-fluid gear grease for special purpose. Lubrication must be examined once a year at least, if there is not any abnormity, it can be put into operation all the same. Otherwise, it should be replaced or supplemented. The metal bellows are filled with 50# mechanic oil for lubrication; the oil must be replaced every two years by user. 10.6 In general, clockwise rotation of output shaft of actuator makes valve close and counter-clockwise rotation makes valve open (viewing downright). If it rotates reversely (i.e. clockwise rotation of output shaft of actuator makes open and counter-clockwise rotation makes valve close, colloquially named reverse actuator), the combining of DQYJ in Fig. 11, “open” and “close” on sector plate in Fig. 23, “open” and “close” on position indicating dial in Fig. 26, wiring between the potentiometer and the BS-2 is different from this operation instruction. Please refer to the real object and this instruction is not subject to change. 10.7 After maintenance and reassembling, it must be reset. After disassembling and reassembling, the sealing elements must be checked carefully. Damaged elements must be replaced in time, and the sealed locations must be tightened close. 10.8 The actuator of ZBTZ must be vertically installed. When it is put into operation, the plug of gas vent must be removed.

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11. ORDERING 11.1 The service environment of the electric actuator must conform to specification. 11.2 Fill in the ordering form with connection size, diameter of stem and maximum extruding length. If the connection size is not consistent with this instruction manual, please consult us for ordering. 11.3 Users can choose the specification of electric actuator by themselves. If there is any trouble, we can choose for user as well. 11.4 The clockwise rotation of handwheel makes valve close. For reverse rotation, it must be declared in order list. 11.5 The 4~20mA valve position signals transmitter is generally provided with 4mA for complete close, and 20mA for complete open. If 4mA for complete open, and 20mA for complete close and other requirements, it must be declared in order list. 11.6 When the electric actuator is connected to power and has not received any 4~20mA set signals from control system, the electric actuator may be in one of the three motion modes: complete open, complete close or remaining in original position. User can choose one of the three modes according to application requirements of his control system, and it must be declared in order list. Standard mode is remaining in original position

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